The final product focused on the device's manufacturability. Certain components, such as the baseplate, body, and rail, were redesigned to be easier to manufacture and assemble. The baseplate is now a single large piece of laser-cut acrylic, so everything sits rigidly on a single surface. The body geometry is also simplified to save on space. The rail was also turned into a separate component to make it easier to manufacture. Linkages and the rail were also manufactured out of UHMWPE (Ultra-High Molecular Weight Polyethylene) and Delrin, respectively, for the final design to improve fatigue performance and reduce friction.
Prototype V3 is the final prototype before our final product. This version aims to create a minimum viable product that includes all the features we intended for the final product. This prototype includes our two-stage powertrain, encoder system, new mounting solution, and optimized sizing. The results from this prototype provided significant insight into the factors we needed to consider for the final product. Belt tension was a major aspect that was tested at this stage, as we wanted to resolve this issue before progressing any further.
In addition to the device's physical components, the electrical and software components were integrated into this design. In this version, we connected all electrical components more securely and finalized the circuitry. Additionally, we were also able to test cycle sensing with the encoder before progressing onto the final product.
This version is built upon the findings of prototype V1, adding a pulley system into the powertrain to help transmit motion across a distance. In this version, a new mounting design is also explored to improve its performance. The design of the linkages was also refined at this stage to reflect what we would like to have in the final product.
After our risk reduction, we settled on the crank slider design. Our first prototype was a basic rendition of our proposed design. This version now had a motor attached and a mounting mechanism as well to explore its performance. This prototype allowed us to evaluate how well the slider performed under loading and how we should organize the linkages.
Two mechanisms were prototyped: slider-rocker and linear rail
Parallel mechanisms exploration